90-860178001
Contents
1. Diameter or Pitch Change RPM Change If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating rpm range will cause higher than normal wear and or damage After initial propeller selection the following common problems may require that the propel ler be changed to a lower pitch e Warmer weather and greater humidity cause an rpm loss e Operating in a higher elevation causes an rpm loss e Operating with increased load additional passengers pulling skiers etc For better acceleration such as is needed for water skiing use the next lower pitch propel ler However do not operate at full throttle when using the lower pitch propeller but not pull ing skiers Because of the many variables of boat design only testing will determine the best propeller for a particular application Available propellers are listed in the Quicksilver Accessories Guide see BOAT IN THE WATER TESTS Maximum RPM Test in the power package Installa tion Manual Page 15 of 48 GASOLINE ENGINES SKI MODELS SPECIAL INFORMATION FOR GASOLINE ENGINES IMPORTANT When selecting a propeller consider this additional information if ap plicable The engines listed in the following chart are equipped with an rpm rev limiter that is set to an upper or limited rpm amount This limit is sli2. 22552 a Cable End Guide b Throttle Lever Stud c Elastic Stop Nut and Washer d Spacer e Cable Barrel f Anchor Stud g Washer h Elastic Stop Nut Page 25 of 48 GASOLINE ENGINES SKI MODELS ATTACHING ADJUSTING THROTTLE CABLE EFI MODELS 1 Place remote control handle in neutral idle position 2 Remove flame arrestor 3 Attach cable to the lowest hole on the throttle body unit following cable manufacturer s instructions 4 Install cable end guide on throttle lever then push cable barrel end lightly toward throttle lever end This places a slight preload on shift cable to avoid slack in cable when moving remote control lever Adjust barrel on throttle cable to align with hole in anchor plate Position cable as shown 75806 74838 Black Scorpion a Throttle Lever b Anchor Plate c Throttle Cable 5 Secure throttle cable with hardware as shown and tighten securely Page 26 of 48 INDEX GASOLINE ENGINES SKI MODELS ATTACHING ADJUSTING SHIFT CABLE ALL MODELS IMPORTANT Velvet Drive Transmission Warranty is jeopardized if the shift lever pop pet ball or spring is permanently removed if the shift lever is repositioned or changed in any manner or if remote control and cable do not position shift lever correctly leat CS a Transmission Shift Lever b Shift Lever MUST BE Over This Letter When Propelling Boat FORWARD c Shift Lever MUST BE Over This Letter When Propelling Boat IN
3. 350 5 7 V8 MPI and 377 6 2 550 cca 700 mca 120 Ah Battery Cables Select proper size positive and negative battery cables using chart Battery should be located as close to engine as possible IMPORTANT Terminals must be soldered to cable ends to ensure good electrical contact Use electrical grade resin flux solder only Do not use acid flux solder as it may cause corrosion and a subsequent failure GASOLINE ENGINES Cable Gauge 3 9m 6009 120mm Page 13 of 48 GASOLINE ENGINES SKI MODELS EFI Electrical System Precautions NOTE All references to EFI models apply to all EFI and MPI engines Avoid damage to the EFI electrical system and components Refer to the following precautions when working on or around the EFI electrical harness or when adding other electrical accessories e DO NOT tap accessories into engine harness e DO NOT puncture wires for testing Probing e DO NOT reverse battery leads e DO NOT splice wires into harness e DO NOT attempt diagnostics without proper approved Service Tools Instrumentation Page 14 of 48 If Quicksilver wiring harness is used and a fused accessory panel is to be installed 40 amp current draw maximum be sure to connect it as shown in wiring diagram Do not connect accessory panel at any other location as wires in wiring harness may not be of sufficient size to handle current load We recommend the use of Quicksilver Inst
4. be fitted with a swan neck to prevent water from entering the tank It is recommended that the exact route and length of the fuel lines be established at the first installation of the engine to prevent problems later in connecting them to the engine All fuel lines must be well secured The holes where the lines run through the bulkheads should be carefully rounded off or protected with rubber grommets This prevents damage to the lines from abrasion INDEX GASOLINE ENGINES SKI MODELS The following but not limited to the following additional fuel connection related points ap plying to all engines unless otherwise stated must be considered Refer to boating stan dards NMMA ABYC etc and Coast Guard regulations for complete guidelines 1 Fuel tank should be mounted below carburetor level if possible or gravity feed may cause carburetor fuel inlet needle to unseat and flooding may result 2 On Gasoline Engines The maximum measured vacuum at the engine s fuel inlet must not exceed 2 in Hg 6 9 kPa at idle rom 3000 full throttle rom and back at idle rom IMPORTANT Vacuum reading higher than specified can cause vapor locking with some of today s fuels It can also cause poor engine performance because of fuel starvation 3 Fuel pickup should be at least 1 in 25mm from the bottom of fuel tank to prevent pick ing up impurities 4 Fuel lines used must be Coast Guard approved USCG Type A1 Diameter of fittin
5. INDEX The following are registered trademarks of Brunswick Corporation Merc MerCathode MerCruiser Mercury Mercury Marine MerCruiser Quicksilver and Ride Guide GASOLINE ENGINES SKI MODELS NOTICE to INSTALLER After Completing Installation These Instructions Should Be Placed With The Product For The Own er s Future Use NOTICE to COMMISSIONING DEALER Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product Owner Table of Contents T 3 Engine Installation 19 Notice to Boat Manufacturer Installer 3 Battery Cable Connection 19 Quicksilver Products 200005 4 Engine Mount Pre Adjustment 20 Installation Products 4 Initial Engine Alignment 22 Torque Specifications 4 Final Engine Alignment 22 Serial Number Decal Placement 4 Seawater Pickup Pump Connection 24 Fuel Octane Requirements Sticker 4 Throttle Shift Cable 25 Engine Rotation 0 e eee ee 4 Fuel Supply Connection 29 ansmission ee 5 Audio Warning System 33 T 6 Electrical Connections 31 Boat Construction 2 2 eee eee 6 Exhaust System Hoses Tubes Exhaust System 00 0 cece ene 9 O ape eee eos be ees wees 31 Fuel Delivery Syste
6. Plate Not used on Ski models 7 Idle Air Control IAC 17 Oil Pressure Audio Warning System 8 Throttle Position TP Sensor 18 Gear Lube Bottle Not used on Ski models 9 Engine Coolant Temperature ECT Sensor 19 Fuel Pressure Switch 10 Electronic Control Module ECM 20 Water Temperature Sender 11 Fuel Pump Relay BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE i PNK PINK PUR PURPLE RED RED I TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK 1HM NHD Q ETE Page 46 of 48 INDEX GASOLINE ENGINES SKI MODELS MIE Water Flow Diagram Gasoline Engines with Seawater Raw Water Cooling System ALL V8 350 AND 377 CID ENGINES NOTE Certain components in the following diagram may look different than on your particu lar power package but the water flow paths remain similar on all engines 1 Seawater Intake 2 Seawater Pump 3 Transmission Cooler 4 Fuel Cooler EFI Models 5 Thermostat Housing and Cover Assembly 6 Engine Water Circulating Pump 7 Engine Block and Cylinder Head Assembly 8 Exhaust Manifold Typical 9 Restrictor Gasket 10 Exhaust Elbow Assembly Typical 11 Water Flow Overboard 75149 Page 47 of 48 GASOLINE ENGINES SKI MODELS Predelivery Inspection Not Check Not Check Applicable Adjust Applicable Adjust CHECK BEFORE RUNNING Drain plug in and petcocks closed Seawater inlet valve open Engine
7. REVERSE d Poppet Ball MUST BE Centered in Detent Hole for Each F N R Position For ward Gear Shown Install Shift Lever Stud in This Hole If Necessary To Center Poppet Ball in For ward and Reverse Detent Holes Som i ii eX 22457 IMPORTANT When installing shift cables be sure that cables are routed to avoid sharp bends and or contact with moving parts All bends must make greater than an 8 inch 203 mm radius DO NOT fasten any items to shift cables NOTE Hefer to shift cable manufacturer s instructions for adjusting the cable Shift lever must be positioned as stated in the preceding steps 74845 a Throttle Lever Stud b Cable End c Locknut Page 27 of 48 GASOLINE ENGINES SKI MODELS ROUTING OF SHIFT CABLES BLACK SCORPION 1 Shift Cable Route shift cable from the starboard to the port side of engine and then between intake manifold and elbow Position cable so it will not interfere with flame arrestor LS aso Wee 74833 a Sta Straps b Shift Cable Fuel Supply Connection Remove plastic plug from fuel inlet hole in casting Apply 592 Loctite Pipe Sealant with Teflon to threads of fuel inlet line connector DO NOT USE TEFLON TAPE To prevent cracking the casting and or fuel leaks turn inlet connector in by hand until finger tight then tighten connector to 1 3 4 to 2 1 4 turns with wrench DO NOT OVERTIGHTEN Inspect for fuel leaks IMPORTANT A flexi
8. between coupling faces when butted together Adjust engine bed height if necessary to obtain proper align ment DO NOT use mount adjustments to adjust engine position at this time IMPORTANT Engine bed must position engine so that a minimum of 1 4 in 6 mm up and down adjustment still exists on all 4 mounts after performing final alignment This is necessary to allow for final engine alignment 2 Ensure that all 4 mounts are still positioned properly then fasten mounts to engine bed with 3 8 in 10 mm diameter lag screws of sufficient length and flat washers Tighten lag screws securely 3 Disconnect overhead hoist and remove sling Final Engine Alignment Page 22 of 48 IMPORTANT Engine alignment MUST BE RECHECKED with boat in the water fuel tanks filled and with a normal load onboard Engine must be aligned so that transmission and propeller shaft coupling centerlines are aligned and coupling faces are parallel within 003 in 0 07 mm This applies to installations with solid couplings as well as flexible couplings 1 Check mating faces on transmission output flange and propeller shaft coupler to make sure they are clean and flat 2 Check that coupling centerlines align by butting propeller shaft coupler against trans mission output flange Shoulder on propeller shaft coupler face should engage recess on transmission output flange face with no resistance NOTE Some propeller shaft couplers may not have a shoulde
9. during the test and the bilge blower should not be running 4 Engine Running and Heat Soak Test a Use 1 meter and 2 thermal couples Place one thermal couple at the flame arrestor to measure the inlet air temperature Place the second thermal couple at the fuel pump to measure the inlet fuel temperature A third thermal couple is needed if the fuel supply line between the tank and the fuel pump is higher than the fuel pump Place the third thermal couple at the highest point of the supply line to measure the temperature of the fuel at that point b Start engine to warm it up After engine is at its normal operating temperature run engine at 1500 rpm in neutral gear for 15 minutes Record both temperature read ings at 5 minute intervals c After 15 minutes running at 1500 rpm shut engine off and continue to record both temperature readings at 5 minute intervals for the next 45 minutes d After the 45 minute heat soak test start engine and idle in neutral gear for 20 min utes Continue to record both temperature readings at 5 minute intervals IMPORTANT If the temperature at either location exceeds specifications the engine compartment will need additional ventilation until both temperatures remain below these specifications INDEX INDEX GASOLINE ENGINES SKI MODELS Exhaust System IMPORTANT It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine and install the exhaus
10. mounts tight Engine alignment Drive unit fasteners torqued Power trim cylinders fasteners tight Battery fully charged and secured All electrical connections tight Exhaust system hose clamps tight All fuel connections tight Correct rotation propeller installed and torqued Throttle shift and steering system fasteners tightened properly Throttle plates open and close completely Crankcase oil level Power trim oil level Stern drive unit oil level Power steering fluid level Closed cooling level Transmission fluid level Alternator belt tension Seawater pickup pump belt tension Power steering pump belt tension Audio warning system operation uu UUUUUUUUUUUUUUUUUUUU tl uu uuduuddutluluduliuucdtLuliuut tl UU U uuu uuu uudtutuuut utu Page 48 of 48 ON THE WATER TEST __ Engine alignment Inboards only otarter neutral safety switch operation Water pump operation Instruments s operation Fuel leaks Oil leaks Water leaks Exhaust leaks lgnition timing _ Idle RPM within specifications Forward Neutral Reverse gear operation __ Steering operation throughout range Acceleration from idle rpm WOT RPM within specifications in forward gear __ Power trim operation Trim tab adjustment __ Boat handling AFTER ON WATER TEST __ Propeller nut torque Fuel oil coolant water and fluid leaks Oil and fluid levels Apply Quicksil
11. sense op eration are major accident prevention measures Hazards or unsafe practices which COULD result in severe personal injury or death Hazards or unsafe practices which could result in minor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for proper in stallation and or operation This installation requirements manual has been written and published by Mercury Marine to aid the boat manufacturer involved in the application and installation of the products de scribed herein It is assumed that these personnel are familiar with marine product application and the installation procedures of these products or like or similar products manufactured and mar keted by Mercury Marine Furthermore it is assumed that they are familiar with if not trained in the recommended installation procedures of these products It is the responsibility of the OEM to select the appropriate engine transom drive package including the correct gear ratio and propeller for a given boat Making an appropriate selec tion requires knowledge of the boat weight length hull design intended use and duty cycle desired speed etc that is uniquely in the possession of the OEM While Mercury employs people capable of assisting the OEM on such issues the final decision rests with the OEM Mercury recommends that any new or unique hull power package combination be thor oughly water
12. tested prior to sale to verify among other things that the boat performs as desired and that the engine runs in the appropriate rpm range We could not possibly know of and advise the marine trade of all conceivable applications and installations which might be achieved and of the possible hazards and or results of each conceivable application or installation We have not undertaken any such wide evalua tion Therefore any manufacturer which or person who applies or installs the product in a manner which does not fulfil the requirements listed herein first must completely satisfy themselves that neither their safety nor the product will be endangered by the application or installation procedure selected It is recommended that a Mercury Marine Field Product Engineer be contacted for assis tance if specific application or installation problems are encountered All information illustrations and specifications contained in this manual are based on the latest product information available at time of publication As required revisions to this man ual will be sent to all OEM boat companies Page 3 of 48 GASOLINE ENGINES SKI MODELS Quicksilver Products Quicksilver gauges remote controls steering systems propeller shaft couplers etc are available for this product Refer to Quicksilver Accessories Guide for complete listing This Guide is available from Attn Parts Department Mercury Marine W6250 W Pioneer Road P O Bo
13. the boat up on plane or to pull up a water skier For engines utilizing fuels containing alcohol and the newer reformulated gasolines See OEM Service Bulletin 95 2 proper ventilation is more critical to prevent vapor locking If a separate air shaft or similar is used to provide engine compartment ventilation or addi tional ventilation care must be taken to prevent seawater and spray from entering it Combustion Air Requirements Engine compartments with natural draft ventilation must have vent openings of sufficient size and location to accomplish the tasks previously outlined IMPORTANT The size of ventilation openings must be increased if any auxiliary equipment is located in the engine compartment The combustion air requirement per engine for the specified engines at Wide Open Throttle are given in the chart below Engine Air Flow Requirements Per Engine Engine Air Requirements at Physical Wide Open Throttle Volume 486 ft 9 Min 5 3 ft 9 0 229 m3 sec 150 L 568 ft Min 5 3 ft MSS PI 0 268 m3 sec 150 L Black Scorpion 527 ft Min Sole j 0 249 m sec 150 L In addition the pressure differential outside engine compartment versus inside engine compartment should not exceed 2 in 51mm of water measured with a manometer at Wide Open Throttle 506 ft 3 Min 5 3 ft 3 PAA 0 239 m3 sec 150 L Page 7 of 48 GASOLINE ENGINES SKI MODELS Page 8 of 48 Compartment Temperature Spec
14. E YELLOW LIGHT DARK j 73371 Page 41 of 48 GASOLINE ENGINES SKI MODELS MIE Gasoline Engine Wiring Diagrams MIE 5 7L Inboard Engines BLK 1 YEL RED 7 RED PUR 6 LIT BLU 8 TAN 3 BRN WHT 10 BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 75754 NOTE BROWN WHITE wire may be used for an Accessory LOAD MUST NOT EXCEED 5 AMPS Page 42 of 48 INDEX GASOLINE ENGINES SKI MODELS A Ignition Components 1 Distributor 2 Timing Lead 3 Knock Sensor 4 Ignition Coil B Starting Charging and Choke Components Alternator Electric Choke Ground Plug Starter Motor Oil Pressure Switch Fuel Pump Circuit Breaker Neutral Safety Switch Starter Slave Solenoid OONOORGQND C Audio Warning Components 1 Oil Pressure Switch 2 Water Temperature Switch 3 Transmission Temperature Switch D Instrumentation Components 1 Oil Pressure Sender 2 Water Temperature Sender 3 See NOTE below Page 43 of 48 GASOLINE ENGINES SKI MODELS MIE 350 Mag MPI Black Scorpion and MX 6 2L MPI Engines Starting and Charging System Harness NOTE laped back BROWN WHITE wire may be used for an Accessory LOAD MUST NOT EXCEED 5 AMPS BLK BLACK BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE PNK PINK 7 PUR PURPLE re wa RED
15. RED 1 A TAN TAN WHT WHITE 1 YEL YELLOW LIT LIGHT DRK DARK GRY 2 PUR 5 TAN BLU 4 RED PUR 6 BLK 1 YEL RED 7 LIT BLU 8 TAN 3 BRN WHT 10 a Page 44 of 48 76062 INDEX GASOLINE ENGINES SKI MODELS A Audio Warning Components 1 Transmission Temperature Switch B Instrumentation Components 1 Oil Pressure Sender 2 Wire Not Used C Charging and Starting Components Alternator Ground Stud Starter 90 Amp Fuse DO NOT REMOVE Circuit Breaker Starter Slave Solenoid Neutral Safety Switch logia GND Positive Power Wire To EFI System Harness Harness Connector To EFI System Harness c Auxiliary Tachometer Lead O Page 45 of 48 GASOLINE ENGINES SKI MODELS MIE 350 Magnum MPI Black Scorpion and MX 6 2L MPI Engines Fuel and Ignition System Harness NOTE All BLACK wires with a ground symbol are interconnected within the EFI system har ness NOTE Component position and orientation shown is arranged for visual clarity and ease of circuit identification 1 Fuel Pump 12 Ignition System Relay 2 Distributor 13 Fuse 15 Amp Fuel Pump Fuse 15 Amp ECM DLC Bat 3 Coil tery Fuse 10 Amp ECM Injector Ignition Knock Module 4 Knock Sensor KS Module 14 Harness Connector To Starting Charging Harness 5 Data Link Connector DLC 15 Positive Power Wire To Engine Circuit Breaker 6 Manifold Absolute Pressure MAP Sensor 16 Shift
16. SKI MODELS RETURN HOSE CONNECTION 75480 a Location for Hot Water Return Install Bayonet Fitting Here Engine Installation NOTICE to INSTALLER Before Starting Installation Read General Information and Installation Require ments completely Battery Cable Connection IMPORTANT Engine electrical system is negative ground IMPORTANT Before connecting battery cables make sure that grounding stud and starter solenoid terminal are free of paint or any other material that could cause a poor electrical connection 1 Connect negative battery cable to grounding stud on flywheel housing Tighten nut securely 72773 a Negative Battery Cable 2 Place rubber boot shipped with engine over end of positive battery cable and con nect to 3 8 in 10 mm terminal on starter Tighten nut securely Page 19 of 48 GASOLINE ENGINES SKI MODELS 3 Coat negative and positive battery connections with Liquid Neoprene After Liquid Neo prene has dried slide rubber boot over positive battery cable connection 74171 a Negative Battery Cable b Positive Battery Cable c 90 Amp System Fuse DO NOT Remove EFI and MPI Models Engine Mount Pre Adjustment 1 Remove hardware holding engine to shipping pallet Attach a suitable sling to lifting eyes on engine Lift engine from pallet with an overhead hoist 2 Remove L shaped shipping bracket from both rear transmission mo
17. a ransmission Identification Plate b Gear Ratio in Forward Gear c Output Flange Rotation Decal in Forward Gear Propeller Rotation Propeller rotation is not necessarily the same as engine rotation Refer to the appropriate following information and drawings for specific information IMPORTANT Use of proper rotation propeller specified on transmission output flange rotation decal is critical since the transmission must be operated in forward gear selector position only to drive boat forward If the wrong rotation propeller is installed and transmission is operated in reverse to propel the boat forward trans mission failure WILL occur On engines which are equipped with Velvet Drive in line a LH propeller is required Page 5 of 48 GASOLINE ENGINES SKI MODELS ENGINE PROPELLER SHAFT INSTALLATION ANGLE COUPLING The transmission and engine should be mounted so that the angle relative to horizontal is as shown in the installation drawings Refer to individual installation drawings for each spe cific engine and transmission Relative to horizontal never install the engine with the front pulley end down IMPORTANT On all engines a high angle of installation front pulley end of engine up along with low transmission oil levels can permit transmission pump cavitation on some models when operating in rough water The coupling is a flange type coupler available through Quicksilver Accessories All cou pler bolts mus
18. a 150 rom change exists between propeller pitches Cold Weather or Extended Storage Draining Instructions If boat is to remain in water after draining seawater inlet hose must be removed and plugged to prevent a syphoning action that may occur allowing seawater to flow from the drain holes or removed hoses t Seawater section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use if the possibility of freezing temper atures exist Failure to comply may result in trapped water causing freeze and or corrosion damage to engine IMPORTANT Boat must be as level as possible to ensure complete draining of cool ing system Page 33 of 48 INDEX GASOLINE ENGINES SKI MODELS CARBURETED MODELS 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from following locations a Port Side cylinder block Avoid product damage Do not disturb the Y fitting when removing the drain plug There is an ignition control Knock Sensor in the upper hole of the fitting This sen sor must not be loosened or removed It is tightened to a critical specification at the factory b Starboard Side Y fitting 75438 a Y fitting c Bottom of exhaust manifolds 75018 a Exhaust Manifold Drain Location Page 34 of 48 INDEX GASOLINE ENGINES SKI MODELS 3 Repeatedly clean out drain holes using a stiff pie
19. antifreeze and tap water Follow the manufacturer s recommendation to protect engine to the lowest tempera ture that it will be exposed to during cold weather or extended storage Reinstall thermostat and cover Torque screws with lockwashers to 30 Ib ft 41 N m 74493 a Thermostat Housing b Gasket c Thermostat d Spacer e Thermostat Housing to Intake Manifold Gasket Page 36 of 48 NDEX GASOLINE ENGINES SKI MODELS EFI AND MPI MODELS 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from the following locations a Port Side cylinder block Avoid product damage Do not disturb the Y fitting when removing the drain plug There is an ignition control Knock Sensor in the upper hole of the fitting This sen sor must not be loosened or removed It is tightened to a critical specification at the factory b Starboard Side Y fitting a Y fitting C Fuel cooler d Bottom of exhaust manifolds ANT dy m NN 3 8 6 SC c XA NS NS uM ATES SL 47 NA RN r a TLL LT T Ll a 75081 a Cylinder Block Drain Location port side b Fuel Cooler Drain Location c Exhaust Manifold Drain Location Page 37 of 48 GASOLINE ENGINES SKI MODELS 3 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained NOTE It may be necessary to lift or bend hoses to al
20. asily accessible for inspection and cleaning The strainer should be installed in water inlet hose after the sea cock water inlet valve to allow operator to shut off water when cleaning strainer Page 17 of 48 GASOLINE ENGINES SKI MODELS Hot Water Heater Installation Information IMPORTANT When connecting a cabin heater or hot water heater certain require ments must be met including but not limited to the following e Supply hose from engine to heater and return hose from heater to engine MUST NOT EXCEED 5 8 in 16 mm I D inside diameter e Make heater connections ONLY at locations indicated in the following informa tion e Refer to manufacturers instructions for complete installation information and procedures IMPORTANT Do not reposition engine temperature switch it must remain where in stalled by factory On closed cooling models heater must be mounted lower than the fill cap on the heat exchanger If the heater is higher than the fill cap on the heat exchanger and some coolant is lost from system an air pocket may form in the closed cooling sys NDEX tem This can cause the engine to overheat SUPPLY HOSE CONNECTION 75473 All Engines If Available a Location For Hot Water Supply Install Bayonet Fitting Here 8 7 71758 All Engines Alternate Location a Location For Hot Water Supply Install Bayonet Fitting Here Page 18 of 48 INDEX GASOLINE ENGINES
21. ater pickup should be located as close to seawater pickup pump inlet as possible and in an area where an uninterrupted solid stream of water will flow past when boat is underway Water inlet hose connections must be made with wire reinforced hose of adequate wall thickness to prevent it from collapsing from pump suction Be sure to secure hose connec tions with hose clamps Secure hose to prevent contact with any moving parts of the engine Select the proper hose from the following chart Seawater Pickup Hose Inner Diameter Gasoline Engines 1 1 4 in 32 mm SEACOCK SIZE oeacock used must have an internal cross sectional area equal to or greater than seawater hose to prevent restricting water flow A brass ball or gate valve is required Select a proper seacock based on the following chart Seacock Size Internal Cross Sectional Area Equal to or Greater Than Size Shown Gasoline Engines 1 1 4 in 32 mm Install the seacock in an area where it will be easily accessible and supported adequately to prevent hose fatigue SEA STRAINER otrainer used must be of sufficient size to ensure that an adequate supply of water will be maintained for cooling engine Select a properly rated seawater strainer based on the fol lowing chart Seawater Strainer Minimum Flow Rate Gasoline Engines 30 114 1 Amounts listed are in gallons per minute and liters per minute The seawater strainer should be installed in an area where it will be e
22. ble fuel line must be used to connect fuel line to engine to absorb deflection when engine is running Ensure that the inlet hose to fuel pump does not interfere with drive belts 1 Install barbed fuel line fittings obtain locally in water separating fuel filter adapter 22551 a Inlet b Outlet Page 28 of 48 INDEX INDEX GASOLINE ENGINES SKI MODELS 2 5 7L Model if remote mounting water separating fuel filter Install inverted flare swivel provided into base of fuel pump Finger tighten and then grip hex fitting on end of fuel pump with wrench while tightening swivel an additional 1 3 4 to 2 1 4 turns with a wrench 75523 a Fuel Pump Fitting 3 Remove shipping cap from fuel fitting on water separating fuel filter bracket NOTE Mount water separating fuel filter in a location that allows easy removal and installa tion 4 Attach fuel line to water separating fuel filter adapter 70573 a Water Separating Fuel Filter Adapter Page 29 of 48 GASOLINE ENGINES SKI MODELS Audio Warning System 1 Install audio warning system horn as follows a Select a location for audio warning horn which meets all of the following e horn can be easily heard yet is out of sight e Accessible for installation or maintenance e horn will not get wet p e Where the 18 in 457 mm long PURPLE wire can be connected to an I terminal termi nal with PURPLE wire attached to it on one of the gauge
23. ce of wire Do this until entire system is drained NOTE It may be necessary to lift or bend hoses to allow water to drain completely Crank engine over slightly to purge any water trapped in seawater pickup pump Do not allow en gine to start 4 Loosen hose clamps and remove the following hoses a From transmission cooler 75510 Typical Transmission Fluid Cooler a Transmission Cooler Hose b From engine circulating pump or remove drain plug if equipped 76038 a Engine Circulating Pump Hose b Drain Plug if equipped Page 35 of 48 GASOLINE ENGINES SKI MODELS c From water inlet hose bottom from seawater pickup pump e Em Ss WATER SEPA RAT FUEL FILTER eS 2 75533 UU 5 After cooling system has been drained completely install drain plugs reconnect hoses and tighten all hose clamps securely a Seawater Inlet Hose IMPORTANT MerCruiser recommends that propylene glycol a nontoxic and envi ronmentally safe antifreeze be used in the seawater section of the cooling system for cold weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 6 For additional assurance against freezing and rust follow these steps a Remove the thermostat housing and thermostat b Fill the engine seawater cooling system with a mixture of
24. erious damage to internal engine parts INDEX GASOLINE ENGINES SKI MODELS Over the last several years engine compartments have been designed to be quieter The most common material used to deaden the engine sound Is some type of insulation material Normally the quieter the engine compartment is the more insulation material used which results in less air space inside The less air space inside the engine compartment the hotter the inside air temperature Attention must be given to the air temperature that is inside this engine compartment while the engine is running or after a period of time after the engine is shut off heat soak Refer to the following information on Engine Compartment Ventilation ENGINE COMPARTMENT VENTILATION General Information According to Boating standards NMMA ABYC etc and Coast Guard regulations the en gine compartment ventilation system has multiple tasks Included are the following 1 To supply the engine with combustion air 2 lomaintain a low temperature in the engine compartment Fresh air should enter the engine compartment as low as possible and the heated air should be discharged from the highest point When sufficient ventilation is not provided too much heat can build up inside of engine compartment and cause vapor locking The engine will not want to restart after it has been shut off for a short period of time If it does restart the engine will quit when given the throttle to get
25. eze and tap water Follow the manufacturer s recommendation to protect engine to the lowest tempera ture that it will be exposed to during cold weather or extended storage c Reinstall thermostat and cover Torque screws with lockwashers to 30 Ib ft 41 N m 74493 a Thermostat Housing b Gasket c hermostat d Spacer e Thermostat Housing to Intake Manifold Gasket Page 39 of 48 GASOLINE ENGINES SKI MODELS THIS PAGE IS INTENTIONALLY BLANK Page 40 of 48 INDEX GASOLINE ENGINES SKI MODELS Quicksilver Instrumentation Wiring Diagrams MIE Gasoline Engine Typical Single Station Installation Refer to gauge manufacturer s instructions for specific connections NOTE 1 Connect Wires Together with Screw and Hex Nut Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection NOTE 2 Power for a Fused Accessory Panel May Be Taken from This Connection Load Must Not Exceed 40 Amps Panel Ground Wire Must Be Connected to Instrument Terminal That Has an 8 Gauge BLACK Ground Harness Wire Connected to it NOTE 3 Taped back BROWN WHITE wire may be used for an accessory LOAD MUST NOT EXCEED 5 AMPS a Audio Warning horn b Tachometer c Oil Pressure d Water Temperature e Battery Meter f Ignition Switch g Read Observe NOTE 1 h Read Observe NOTE 1 and 2 BLU BLUE i Read Observe NOTE 3 GRY GRAY j To Engine Wiring Harness NO ORANGE z BUR RED TAN WHIT
26. ghtly above the normal operat ing range of the engine and is designed to help prevent damage from excessive en gine rpm Once the rpm drop into the recommended operating rpm range normal en gine operation resumes Engine Rev Limiter Engine Recommended Operating ian RPM Range Setting Throttle Shift Remote Control and Cables Page 16 of 48 Shift control and shift cable MUST position transmission shift lever EXACTLY as stated in the specific power package Installation Manual or transmission failure may occur Damage caused to transmission as a result of improper shift lever positioning will not be covered by warranty To ensure proper shift and throttle operation we recommend the use of a Quicksilver remote control and cables Refer to Quicksilver Accessories Guide for selection However if a control other than Quicksilver is to be used control must provide a shift cable travel of 2 3 4 in 70 mm INDEX GASOLINE ENGINES SKI MODELS Seawater Connections General Information SEAWATER PICKUP AND HOSE IMPORTANT DO NOT install water pickup directly in line with propeller as pickup may create turbulence and allow air to flow into the propeller slipstream This will cause propeller ventilation and will adversely affect boat performance Water pickup must be large enough to permit sufficient water flow to engine seawater pickup pump for adequate engine cooling Pickup also must supply a positive head while underway W
27. gs and lines must not be smaller than 5 16 in 8 mm I D on 350 cid 5 7L and Black Scorpion engines Diameter of fittings and lines must not be smaller than 3 8 in 10 mm I D on 377 cid 6 2L engines 5 Larger diameter than previously specified lines and fittings must be used on installa tions requiring long lines or numerous fittings 6 Fuel line s should be installed free of stress and firmly secured to prevent vibration and or chafing Sharp bends in fuel lines should be avoided 8 A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine to absorb deflection when engine is running SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS The electric fuel pump and factory installed water separating fuel filter have been carefully designed to function properly together Do not install additional fuel filters and or water separating fuel filters between fuel tank and engine The installation of additional filters may cause e Fuel Vapor Locking e Difficult Warm Starting e Piston Detonation Due to Lean Fuel Mixture e Poor Driveability Page 11 of 48 GASOLINE ENGINES SKI MODELS SPECIAL INFORMATION FOR ALL GASOLINE ENGINES Page 12 of 48 Avoid gasoline fire or explosion Improper installation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and or cause a fuel leak IMPORTANT The following information is provided to ensure proper installatio
28. icable to reduce from the 4 in 102 mm to 3 in 76 mm Refer to the Quicksilver Accessories Guide for kit part number Page 9 of 48 GASOLINE ENGINES SKI MODELS Fuel Delivery System GENERAL Page 10 of 48 Boating standards NMMA ABYC etc and Coast Guard regulations must be ad hered to when installing fuel delivery system The main concern of a boat s fuel system is safety this must be achieved through a techni cally sound installation and constant inspection The fuel system from the filler pipe to the fuel pump is the same in principle for all boats The fuel tank is an integrated component of the boat Refer to the special information on service and maintenance that you have received from the tank manufacturer NOTE On Ski Boat Applications If during testing for a particular application you experi ence fuel starvation in sharp high speed turns baffles or a fuel sump may be needed in the tank to help correct this condition Only a few points related to function and safety are listed here Refer to boating standards NMMA ABYC etc and Coast Guard regulations for complete guidelines e All connections should be on the upper side of the tank e he drain plug at the lowest point on the tank serves to permit the removal of water and sediment e The filler pipe outer diameter should be at least 2 in 51 mm e The tank breather pipe must have an inner diameter of at least 1 2 in 13 mm and must
29. ifications Air temperatures inside of engine compartments have been measured in excess of 200 F 82 C The long term effect to fuel system components running at these excessive temper atures is not known at this time According to specification SAE J1223 for Marine Carburetors The carburetor shall be capable of operation throughout an ambient air temperature range from 20 to 176 F 7 to 80 C without failure Carburetors throttle body injection TBI units and components for multi port EFI systems used by MerCruiser meet this specification Under the hottest outside air temperature condition at which the boat will be operated the air temperature inside the engine compartment measured at the flame arrestor shall not exceed 176 F 80 C Also the temperature of the fuel being supplied to the engine shall not exceed 110 F 43 C at any location between the fuel tank and the engine s fuel pump Since many factors influence engine compartment temperature temperature measure ments should always be carried out as follows Compartment Temperature Testing Test as follows 1 The boat being tested shall be a standard production boat fitted as it would be for delivery to a dealer 2 Temperature test meter used shall be of the type that can be read without opening the engine cover 3 During the test in Step 4 engine compartments are to remain closed No outside air is to be forced into the engine compartment
30. ine alignment MUST BE CHECKED with boat in the water fuel tanks filled and with a normal load onboard Avoid engine damage Ensure that cooling water is supplied to the engine if it will be run with boat out of the water See instructions in the Operation Maintenance and Warranty Manual entitled Flushing Cooling System for instructions on con necting flush device ENGINE IDLE SPEED ADJUSTMENT CARBURETED MODELS Page 32 of 48 The engine should idle at rpm as specified in Operation Maintenance and Warranty Manual with engine at normal operating temperature If idle speed is incorrect proceed as follows IMPORTANT In order to properly set idle speed the ignition module MUST BE locked in the Base Timing Mode This is necessary because of the Idle Speed Control feature that exists in the ignition module This must be done before the key switch is turned to the ON or START position 1 Connect a shop tachometer to engine 2 Using a jumper wire connect the ignition system Timing Lead PUR WHT wire to a good engine ground This locks the ignition module into the Base Timing Mode Refer to Engine Wiring Harness diagram in this manual 3 Start engine and place the remote control lever in NEUTRAL idle position 4 Adjust idle speed to 650 rpm otop engine Readjust cable barrel and reinstall the throttle cable INDEX GASOLINE ENGINES SKI MODELS IMPORTANT Be sure to disconnect the jumper wire f
31. low water to drain completely Crank engine over slightly to purge any water trapped in seawater pickup pump Do not allow en gine to start 4 Remove hoses from the following locations a Water inlet hose bottom from seawater pump LR a im f fA 7f i n Se j V iti MILI N 75533 a Seawater Inlet Hose b Hose from transmission cooler EE n L E Ea MA Ww ek FRR d BM c j S e ee i JOD a os 75510 Typical Transmission Fluid Cooler a Transmission Cooler Hose Page 38 of 48 INDEX GASOLINE ENGINES SKI MODELS c From engine circulating pump or remove drain plug if equipped 76038 a Engine Circulating Pump Hose b Drain Plug if equipped 5 After cooling system has been drained completely install drain plugs reconnect hoses and tighten all hose clamps securely IMPORTANT MerCruiser recommends that propylene glycol a nontoxic and envi ronmentally safe antifreeze be used in the seawater section of the cooling system for cold weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 6 For additional assurance against freezing and rust follow these steps a Remove the thermostat housing and thermostat b Fill the engine seawater cooling system with a mixture of antifre
32. m 10 IPredelivery Preparation 32 Battery 2 0 ccc ee eens 13 Battery Connection 32 Battery Cables sss 13 Test Running Engine 32 EFI Electrical System Precautions 14 Boat In The Water Tests 32 Instrumentation anaana e ee eee 14 Cold Weather or Extended Storage Propeller Selection 0005 15 Draining 878 TENERE NER NIRE OR DRE 33 Throttle Shift Remote Control and 97 MT 16 Seawater Connections General Information 0 0 c cece ees 17 Hot Water Heater Installation Information 18 Predelivery Inspection 48 90 860178001 APRIL 2000 Printed in U S A 2000 Mercury Marine Page 1 of 48 GASOLINE ENGINES SKI MODELS THIS PAGE IS INTENTIONALLY BLANK Page 2 of 48 INDEX GASOLINE ENGINES SKI MODELS General Information Notice to Boat Manufacturer Installer Throughout this publication Warnings and Cautions accompanied by the International Hazard Symbol A are used to alert the manufacturer installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe Them Carefully These Safety Alerts alone cannot eliminate the hazards that they signal Strict com pliance to these special instructions when performing the service plus common
33. mounts 5 After engine has been properly aligned secure engine mounts as shown 6 Torque clamping screws and nuts on all 4 mount brackets to 50 Ib ft 68 Nm 7 Tighten locknuts on all 4 mounts securely Page 23 of 48 GASOLINE ENGINES SKI MODELS 8 Bend one of the tabs on tab washer down onto flat of adjusting nut 70646 a Clamping Screws and Nuts b Locknut c Tab On Tab Washer d 1 3 4 in 45 mm 9 Connect propeller shaft coupler to transmission output flange Secure coupling together with bolts lockwashers and nuts Torque to 50 Ib ft 68 Nm Seawater Pickup Pump Connection 1 Remove shipping cap Connect seawater inlet hose to inlet fitting bottom hose on sea water pump 75533 a Seawater Inlet Hose Page 24 of 48 INDEX GASOLINE ENGINES SKI MODELS Throttle Shift Cable Lubricate cable ends and barrels and then attach to engine and transmission IMPORTANT When installing throttle cable be sure that cables are routed in such a way as to avoid sharp bends and or contact with moving parts DO NOT fasten any items to throttle cable ATTACHING ADJUSTING THROTTLE CABLE CARBURETED MODELS Lubricate cable ends and barrels 2 Place remote control throttle lever in idle position and attach cable end guide to carbure tor throttle lever as shown 3 Grasp cable behind barrel and push lightly as shown Adjust cable barrel to align hole with anchor stud then slide barrel onto stud
34. n of brass fittings or plugs installed into fuel pump or fuel filter base Use 592 Loctite Pipe Sealant with Teflon on threads of brass fittings or plugs DO NOT USE TEFLON TAPE Brass fittings or plugs should first be threaded into fuel pump or fuel filter base until finger tight Fittings or plugs should then be tightened an additional 1 3 4 to 2 1 4 turns using a wrench DO NOT OVERTIGHTEN To prevent overtightening when installing a fuel line the brass fittings should be held with a suitable wrench as fuel line connectors are tightened securely INDEX GASOLINE ENGINES SKI MODELS Battery IMPORTANT Boating industry standards BIA ABYC etc federal standards and Coast Guard regulations must be adhered to when installing battery Be sure battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations IMPORTANT Engine electrical system is negative ground It is recommended re quired in some states that battery be installed in an enclosed case Refer to regula tions for your area Select a battery that meets all of the following specifications 1 12 volt marine type 2 Tapered post connector or side terminal connectors Do not use a battery with wing nut connectors 3 Reserve battery capacity rating of at least Engine cid L Minimum Required Cranking cyl type Battery Size V8 Carb 350 5 7 3 5 cca 475 mca 90 Ah
35. r on mating face On these installations use a straight edge to check centerline alignment 3 Check for angular misalignment by hand holding coupling faces tightly together and checking for a gap between coupling faces with a 003 in 0 07 mm feeler gauge at 90 E INCORRECT INCORRECT CORRECT 22457 INDEX GASOLINE ENGINES SKI MODELS 4 f coupling centerlines are not aligned or if coupling faces are more than 003 in out of parallel adjust engine mounts a TO ADJUST ENGINE UP OR DOWN Loosen locking nut a on mounts requiring adjustment and turn adjusting nuts in desired direction to raise or lower IMPORTANT Both front mount or rear mount adjusting nuts must be turned equally to keep engine level from side to side ee Ce N p A e SE 70645 a Locking Nut b Adjusting Nut c Clamping Screw s and Nut s with Lockwasher s b TO MOVE ENGINE TO THE LEFT OR RIGHT Loosen clamping screws and nuts on all 4 mount brackets and move engine to the left or right as necessary to obtain proper alignment A small amount of adjustment can be obtained with slot on front end of some mounts Loosen lag screws which fasten mounts to engine bed and move engine as required Retighten lag screw securely NOTE Some rear mounts have one 1 clamping screw and nut on each side IMPORTANT Large diameter of mount trunnion MUST NOT extend over 1 3 4 in 45 mm from mount brackets on any of the
36. ring Harness Connection Exhaust System Hoses Tubes Connection 1 Exhaust hoses tubes must be connected to exhaust elbows so that they do not restrict the flow of discharge water from the elbow If hoses tubes are connected incorrectly a hot spot in the hose tube can occur and can eventually burn through 2 Exhaust hoses tubes should be secured at each connection with at least 2 hose clamps 22032 a Correct b Incorrect IMPORTANT S pipes must be routed under the transmission mounts 74832 a S Pipe b Transmission Mount Page 31 of 48 GASOLINE ENGINES SKI MODELS Predelivery Preparation NOTICE to INSTALLER Before starting Predelivery read General Information and Installation Require ments completely Battery Connection IMPORTANT Engine electrical system is negative ground 1 Connect engine positive battery cable usually red to positive battery terminal 2 Connect engine negative battery cable usually black to negative battery termi nal 3 Make sure that all battery terminal connections are tight and then coat connections and terminals with a battery terminal anti corrosion spray to help retard corrosion Test Running Engine t If engine is to be tested on land propeller must be removed IMPORTANT If engine is to be tested on land water must be supplied to seawater pickup pump DO NOT run engine above 1500 rpm Boat In The Water Tests IMPORTANT Eng
37. rom the ignition system test lead before attempting to resume normal operations If the jumper wire is left in place the ignition module will operate in the Base Timing Mode This means that the addition al timing advance features would not be functioning 6 Remove the jumper wire from the timing lead ENGINE IDLE SPEED EFI MODELS Engine should idle at rom as specified in Operation Maintenance and Warranty Manual with engine at normal operating temperature If idle speed is incorrect proceed as follows 1 Ensure that throttle cable has been adjusted properly 2 If idle speed is still not correct it may be necessary to perform EFI System Diagnostic Tests on the idle circuit Refer to the appropriate MerCruiser Service Manual for proce dures WIDE OPEN THROTTLE TEST IMPORTANT To run engine at full throttle before the break in period is complete fol low this procedure 1 Start engine and run at idle rpm until normal operating temperature is reached 2 Run boat up on plane 3 Advance engine rpm in 200 rpm increments until engine reaches its maximum rated rpm To test if the correct propeller has been installed operate boat with normal load on board at WOT and check rpm with an accurate tachometer Engine rpm should be near top of the specified range so that under a heavy load engine speed will not fall below specifications If engine speed is too high replace propeller with a higher pitch propeller Normally
38. rumentation and Wiring harness es On dual sta tion applications oil pressure and water temperature senders on engine must be changed Refer to Quicksilver Accessories Guide for selection The 4 basic gauges that must be used with the engine are e Tachometer e Oil Pressure e Water Temperature e Voltmeter Route instrumentation wiring harness back to engine making sure that harness does not rub or get pinched If an extension harness is required be sure to secure connection proper ly Fasten harness es to boat at least every 18 in 460mm using appropriate fasteners INDEX GASOLINE ENGINES SKI MODELS Propeller Selection GENERAL INFORMATION IMPORTANT Installed propeller must allow engine to run at its specified maximum wide open throttle revolutions per minute rpm Use an accurate service tachometer to verify engine operating rpm It is the responsibility of the boat manufacturer and or the selling dealer to equip the power package with the correct propeller s Specified engine wide open throttle WOT and oper ating rom range are listed in the Operation Maintenance and Warranty Manual attached to the engine Select a propeller that will allow the engine power package to operate at or near the top end of the recommended wide open throttle operating rom range with a normal load There is a change in rom between propeller diameter or pitches that is generalized in the following chart MIE Models
39. s or to a 12 volt source on switched side of ignition switch t horn is not external ignition proof therefore DO NOT mount horn in engine or fuel tank compartments as this would be a fire or explosion hazard b Mount horn in desired location Secure horn to wire bundle with sta strap provided p c Connect PURPLE wire from horn to any I terminal or ignition switch Tighten con nection securely Refer To Wiring Diagram d Connect TAN BLUE wire from horn to TAN BLUE wire from instrument harness re fer to Wiring Diagram e Place the small transparent decals on the bottom of the water temperature gauge and the oil pressure gauge f Place the large decal on the instrument panel or other appropriate location in easy view of the operator ALARM INDICATES LOW OIL OR OVERHEATING APPLY THE PROPER DECAL TO THE DASHBOARD OR OTHER APPROPRIATE LOCATION 9 AUDIO WARNING HORN WILL SOUND WHEN 1 ENGINE OIL PRESSURE IS TOO LOW 2 ENGINE WATER TEMP IS TOO HOT OR 3 TRANSMISSION TEMPERATURE IS TOO HOT TO TEST THE AUDIO WARNING HORN TURN KEY TO ON POSITION ENGINE OFF 75434 a Small Decal Transparent b Large Decal 2 Test audio warning system as indicated on dashboard decal Page 30 of 48 INDEX GASOLINE ENGINES SKI MODELS Electrical Connections 1 Connect instrumentation wiring harness to engine and secure with clamp jl Dhi 7 ZA 75532 a Instrumentation Wi
40. t be SAE Grade 8 Metric Grade 10 9 or better with a shoulder grip length long enough to pass through the face mating plane of couplers All coupler bolts must be torqued to 50 Ib ft 68 N m PROPELLER SHAFT DIAMETER Propeller shaft diameter should be of sufficient size for the type of application Installation Requirements Boat Construction ENGINE BED Distance between starboard and port engine mount is 22 1 2 in 572 mm Engine bed must position engine so that a minimum of 1 4 in 6 mm up and down adjustment still exists on all 4 mounts after performing final engine alignment This is necessary to allow for realigning engine in the future NOTE Although the engine mounts allow some adjustment it is a good practice to ensure that the front and rear mount locations in the vessel are in parallel planes This may be checked by tying a string from the left front mount location to the right rear mount location and another from right front to left rear The strings should touch where they cross ENGINE COMPARTMENT Page 6 of 48 t Boating standards NMMA ABYC etc and Coast Guard regulations must be ad hered to when constructing the engine compartment Care must be exercised in the design and construction of the engine compartment Seams must be located so that any rain water that may leak through the seams is directed away from the air intake system Water that runs onto the air intake may enter the engine and cause s
41. t system Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine Damage caused by water in the engine will not be covered by MerCruiser Warranty unless this damage is the result of defective part s Determine if exhaust elbow risers are required by taking measurements a and b with boat at rest in the water and maximum load aboard Subtract b from a to find c If c is less than specified in chart select appropriate size exhaust elbow riser kit and exhaust exten sion kit if applicable that will correctly position exhaust elbow c a Minus b All Models c Must Be 13 in 330 mm or More 22457 Typical Installation Shown a From Waterline To Top Of Transom b From Highest Point On Exhaust Elbow To Top Of Transom c Equals a Minus b d Waterline At c Rest e System must not cause excessive back pressure when measured at exhaust elbow out lets Back pressure MUST NOT exceed 2 psi 14 kPa Minimum exhaust hose sizes are given in chart Minimum Exhaust Outlet Hose Size 3 1 2 in 88 9 mm e Exhaust hoses must be secured at each connection with two 2 hose clamps e Exhaust hoses must be connected to exhaust elbows so that they do not restrict the flow of discharge water from the elbow If hoses are connected incorrectly a hot spot in the hose can occur and can eventually burn through NOTE A kit is available when appl
42. unts Retorque mount bracket attaching screw to 48 Ib ft 65 N m IMPORTANT Engine mounts must be adjusted as explained in Steps 3 and 4 to cen ter mount adjustment and establish a uniform height on all mounts 3 Ensure that distance from bottom of all 4 engine mounts 2 front 2 rear mount to bottom of trunnion equals 2 5 8 in 1 16 in 10 mm 2 mm If not loosen mount locking nut and turn adjusting nut in direction required to obtain proper dimension then retighten locking nut Be sure to leave mount positioned so that slot is forward d Page 20 of 48 INDEX GASOLINE ENGINES SKI MODELS 4 Loosen clamping screws and nuts on all 4 engine mount brackets to ensure the follow ing e Large diameter of mount trunnion extended as shown Mount base slotted mounting hole forward if so designed Each mount base is downward Tighten clamping screws and nuts slightly to prevent moving in or out Mounts must be free to pivot when installing engine 70140 Front Mount 70645 Rear Mount a Locking Nut b Adjusting Nut c Trunnion Clamp Screw s And Nut s With Lockwasher s d Slot Forward e 3 8 in 1 16 in 10 mm 2 mm f 2 5 8 in 1 16 in 67 mm 2 mm g Mount Trunnion Page 21 of 48 GASOLINE ENGINES SKI MODELS Initial Engine Alignment 1 Lift engine into boat and position on engine bed so that transmission output flange and propeller shaft coupler are visibly aligned no gap can be seen
43. ver Corrosion Guard to engine package
44. x 1939 Fond du Lac WI 54936 1939 Installation Products Quicksilver 2 4 C Marine Lubricant with Teflon 92 825407A3 Quicksilver Liquid Neoprene 92 25711 2 Quicksilver Perfect Seal 92 34227 1 Torque Specifications DESCRIPTION Engine Mount Bracket Screw Trunnion Clamping Screw and Nut Propeller Shaft Coupling Screw and Nut Exhaust Manifold Screw Fuel Line Inlet Fitting See Note Note Refer to Fuel Delivery System Special Information For All Gasoline Engines Serial Number Decal Placement There are three engine serial number decal strips provided with each power package One should be used for each of the following e Engine Specification Decal e Warranty Registration Card e Operation Maintenance and Warranty Manual identification page Engine Rotation Engine rotation is described when observed from the rear of the engine transmission end looking forward water pump end Engine rotation is indicated on engine specifications and serial number decal Page 4 of 48 INDEX GASOLINE ENGINES SKI MODELS Transmission IDENTIFICATION Velvet Drive Transmissions On Velvet Drive In Line Transmissions the gear ratio in forward gear is marked on trans mission identification plate Transmission output shaft rotation and propeller rotation re quired in forward gear is indicated on a decal on transmission case Transmission rotation is described when viewed from the rear of transmission 22556
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